Interior vehicle trim panel made of a natural fiber composite material

Abstract

Vehicle interior trim part (1) comprising a natural fiber composite material, comprising: a decorative layer (10); a rigid support structure (30), in particular an over-injected rigid support structure (30); a natural fiber reinforced plastic substrate (20), in particular an NFPP substrate, arranged between the decorative layer (10) and the support structure (30); wherein the decorative layer (10) comprises a natural fiber fabric layer (11) which is at least partially visible from the outside, and wherein the support structure (30) has a plurality of fastening elements (31) and / or stabilizing elements (32).

Description

[0001] The present invention relates to a vehicle interior trim part comprising a natural fiber composite material. The vehicle interior trim part can be a decorative trim or panel part, in particular as part of a door panel, a center console, a front console, a roof panel, or the like.

[0002] Vehicle interior trim parts generally have particularly high quality requirements. At the same time, the need for environmentally friendly solutions cannot be ignored in this area either. To meet these requirements, composite materials that incorporate natural fibers are particularly promising for the production of vehicle interior trim parts, as they can combine a variety of positive properties such as stability, low weight, and improved environmental compatibility. Accordingly, various materials and material combinations with composite materials that incorporate natural fibers are known in the state of the art. However, these still require improvement, particularly with regard to their quality and environmental compatibility.

[0003] It is therefore an object of the present invention to provide an alternative and, in particular, improved vehicle interior trim part made of a natural fiber composite material. This improvement may be based on improved environmental compatibility.

[0004] This object is achieved by a vehicle interior trim part with a natural fiber composite material according to claim 1. Particular embodiments and further developments are the subject of the dependent claims and the following description.

[0005] The proposed vehicle interior trim part with a natural fiber composite material comprises a decorative layer, a rigid support structure, and a natural fiber-reinforced plastic substrate arranged between the decorative layer and the support structure. The rigid support structure can be a back-injected rigid support structure. The substrate can be an NFPP (natural fiber polypropylene composite substrate). The decorative layer consists of a natural fiber fabric layer that is at least partially visible from the outside. In other words, the fabric layer forms one side of the vehicle interior trim part that is at least partially visible when the vehicle interior trim part is used as intended inside a vehicle. The support structure comprises a plurality of fastening elements and / or stabilizing elements. The fastening elements can be provided for mounting the vehicle interior trim part within a vehicle.The fastening elements may include doghouses, clamp towers, locating pins, locking projections, or the like. The stabilizing elements may be provided for structural support of the vehicle interior trim part, in particular for structural support of the substrate and decorative layer. The stabilizing elements may include ribs, honeycombs, or the like. Furthermore, the support structure may comprise channels for the flow of injected material.

[0006] The combination of the substrate with the other layers provides a factually and visibly increased amount of natural components and at the same time meets at least the quality requirements for vehicle interior trim parts.

[0007] The substrate comprises an A-side and a B-side arranged opposite each other. Generally, the A-side is the side facing the vehicle interior during intended use. Thus, the decorative layer is provided on the A-side of the substrate, while the support structure is provided on the B-side of the substrate.

[0008] The support structure may comprise or consist of a polymer material. The polymer material may be PP (polypropylene), talc-filled PP, PPGF (glass fiber reinforced PP), foamed plastic, in particular foamed PP, and / or natural material-filled plastic, in particular natural material-filled PP. The support structure may consist of talc-filled PP with a talc content of 10 to 50 wt.%, in particular 20 to 40 wt.%. The support structure may consist of PPGF with a glass fiber content of 10 to 50 vol.%, in particular 20 to 40 vol.%. The support structure may consist of a plastic, in particular PP, filled with 10 wt.% to 30 wt.%, in particular 20 wt.%, natural material. The support structure may consist, for example, of PP reinforced with 20 wt.% hemp fibers, also known as NAFILean.

[0009] The substrate can consist of natural fibers and polymer fibers. The natural fibers can be or include flax, kenaf, hemp, miscanthus, bamboo, jute, or wood fibers. The polymer fibers can be or include PP and / or PET fibers. If the substrate consists only of natural fibers and polymer fibers, the proportion of natural fibers can be at least 40 wt.%, at least 50 wt.%, at least 60 wt.%, or at least 70 wt.%, and / or at most 80 wt.% or 90 wt. The proportion of natural fibers can be, for example, between 45 and 50 wt.%, in particular 48 wt.%. The polymer fibers can comprise or consist of recycled polymer fibers. The polymer fibers can comprise or consist of colored polymer fibers, in particular differently colored polymer fibers. The substrate can have an areal density of 500 g / m 2 up to 2400 g / m 2 , especially 1000 g / m 2 have.

[0010] The fabric layer and / or decorative layer can consist of natural fibers and a polymer. The natural fibers can be embedded in a polymer matrix. The fabric layer can consist of a pre-impregnated, in particular dry pre-impregnated, natural fiber composite material. The natural fibers can be or include flax, kenaf, bamboo, or hemp fibers. The polymer can be or comprise PP. If the fabric layer consists only of natural fibers and a polymer, the proportion of natural fibers can be at least 30 wt.%, at least 50 wt.%, at least 60 wt.%, or at least 70 wt.% and / or not more than 80 wt.% or 90 wt. The fabric layer can be an impregnated, laminated, or mixed fabric layer, in particular a fabric layer made of natural fibers that is impregnated, laminated, or mixed with a thermoplastic.The fabric layer can, for example, be a film, in particular a prepreg film, comprising a fabric, in particular a woven natural fabric, impregnated or laminated with a thermoplastic. The decorative layer and / or the fabric layer can have an areal density of 100 g / m². 2 up to 2500 g / m2, especially from 500 g / m 2 up to 580 g / m 2 and in particular 540 g / m 2 The fabric layer may comprise natural, bleached and / or dyed natural fibers.

[0011] The fabric layer may comprise a first type of natural fiber and a second type of natural fiber that differs from the first type. The first type of natural fiber and the second type of natural fiber may differ in at least one property related to tensile strength and color. The difference in tensile strength may be between 50 MPa and 500 MPa, in particular between 100 MPa and 200 MPa.

[0012] The fabric layer can comprise a plurality of untwisted natural fiber yarns or low-twist natural fiber yarns or twisted natural fiber yarns. The fabric layer can comprise at least one plastic, blended, and / or metallic yarn. The fabric layer can comprise a plurality of woven natural fiber yarns, in particular in a twill weave or unidirectional weave or biaxial weave or patterned. In other words, the fabric layer can have different weave types, in particular twill, unidirectional, bidirectional, and / or patterned weave types, and / or different yarn types, in particular untwisted, low-twist, and / or twisted yarn types. The fabric layer can comprise a two-color pattern with a first color in the warp direction and a second color in the weft direction, or any multi-color pattern with, for example, more than one color in the warp direction and more than one color in the weft direction.

[0013] The decorative layer can be arranged directly adjacent to and in contact with the substrate. The decorative layer can consist only of the fabric layer. Alternatively, the decorative layer can comprise one or more further layers arranged between the fabric layer and the substrate. Depending on the interior requirements, the one or more further layers can include adhesive layers, protective layers, foam layers, or the like. Furthermore, the decorative layer can include a cover layer provided on a side of the fabric layer opposite the substrate, i.e., the fabric layer can be arranged between the cover layer and the substrate. The decorative layer can be an at least partially transparent or translucent layer and can be colored and / or tinted. The decorative layer can include a thermoplastic binder.The support structure can be arranged directly adjacent to the substrate and in contact with it.

[0014] The proposed vehicle interior trim part can be manufactured in various ways, including, in particular, one-shot molding, back-injection molding, and / or one-shot molding with back-injection molding. For example, in a first step, the decorative layer and the substrate can be preformed using a compression molding process. In a second step, the support structure can be back-injected onto the preformed decorative layer and the substrate. The fabric layer can be provided as a semi-finished product using dry prepreg. Alternatively, film caulking or impregnation with thermoplastic powder can be used within a standard lamination process using pressure and heat. The coloring of the fabric layer can be achieved by bleaching and / or dyeing, in particular by dyeing the natural fibers, yarn, or fabric.If the yarn is dyed, a two-tone pattern of the fabric can be provided by using differently colored yarns in the warp and weft directions.

[0015] Several embodiments have been disclosed herein. From the following detailed description, which shows and describes two exemplary embodiments of the invention, further embodiments of the present invention and suitable combinations of features will become apparent to those skilled in the art. Accordingly, the figures and the detailed description are to be considered as exemplary and not restrictive. Recurring features in the description of the accompanying figures are marked with the same reference numerals in which Fig. 1 shows a schematic cross-sectional view of a first embodiment of a vehicle interior trim part and Fig. 2 shows a schematic cross-sectional view of a second embodiment of a vehicle interior trim part.

[0016] In the following, recurring features are described once for all figures. Reference is made to individual figures only where appropriate or where differences or alternatives can be identified.

[0017] As in Fig. 1 and Fig. 2, the vehicle interior trim part 1 with a natural fiber composite material comprises a decorative layer 10, a rigid support structure 30, and a natural fiber-reinforced plastic substrate 20 arranged between the decorative layer 10 and the support structure 20. The rigid support structure 20 is a back-injected rigid support structure 20. Here, the substrate is an NFPP substrate (natural fiber polypropylene composite material substrate). The decorative layer 10 comprises a natural fiber fabric layer 11 that is at least partially visible from the outside. In other words, the fabric layer 11 forms one side of the vehicle interior trim part 1 that is at least partially visible when the vehicle interior trim part 1 is used as intended inside a vehicle. The substrate 20 comprises an A-side and a B-side that are arranged opposite one another. The A-side is the side that faces the vehicle interior during intended use.Thus, the decorative layer 10 is provided on the A-side of the substrate 20, while the support structure 30 is provided on the B-side of the substrate 20. The support structure 30 comprises a plurality of fastening elements 31 and stabilizing elements 32. The fastening elements 31 can be provided for mounting the vehicle interior trim part 1 within a vehicle. The fastening elements 32 can include doghouses, clamp towers, locating pins, locking projections, or the like. The stabilizing elements 32 can be provided for structural support of the vehicle interior trim part 1, in particular for structural support of the substrate 20 and the decorative layer 10. The stabilizing elements 32 can include ribs, honeycombs, or the like. The support structure 30 can comprise channels for the flow of injected material.

[0018] The support structure 30 here comprises a polymer material. The polymer material can be PP (polypropylene), talc-filled PP, PPGF (glass fiber reinforced PP), foamed plastic, in particular foamed PP, and / or natural material-filled plastic, in particular natural material-filled PP. The support structure 30 can consist of talc-filled PP with a talc content of 10 to 50 wt.%, in particular 20 to 40 wt.%. The support structure 20 can consist of PPGF with a glass fiber content of 10 vol.% to 50 vol.%, in particular 20 vol.% to 40 vol.%. The support structure 30 can consist of a plastic, in particular PP, filled with 10 wt.% to 30 wt.%, in particular 20 wt.%, natural material. The support structure 30 can consist, for example, of PP reinforced with 20 wt.% hemp fibers, also known as NAFILean.

[0019] The substrate 20 consists of natural fibers and polymer fibers. The natural fibers can be or include flax, kenaf, hemp, miscanthus, jute, bamboo, or wood fibers. The polymer fibers can be or include PP and / or PET fibers. The proportion of natural fibers is at least 40 wt.% and can be at least 50 wt.%, at least 60 wt.%, or at least 70 wt.%, and / or at most 80 wt.% or 90 wt.%. The proportion of natural fibers can be, for example, between 45 and 50 wt.%, in particular 48 wt.%. The polymer fibers can comprise or consist of recycled polymer fibers. The polymer fibers can comprise or consist of colored polymer fibers, for example, differently colored polymer fibers. This could reduce the requirements for providing recycled polymer fibers. Depending on the material mixture, the substrate 20 can have an areal density of 500 g / m 2 up to 2400 g / m 2, especially 1000 g / m 2 have.

[0020] The fabric layer 11 consists of natural fibers and a polymer. The natural fibers are embedded in a polymer matrix. The fabric layer 11 consists of a pre-impregnated, in particular dry pre-impregnated, natural fiber composite. The natural fibers can be or include flax, kenaf, bamboo, or hemp fibers. The polymer can be or comprise PP. The proportion of natural fibers is at least 30 wt.% and can be at least 50 wt.%, at least 60 wt.%, or at least 70 wt.% and / or at most 80 wt.% or 90 wt. The fabric layer 11 can be an impregnated, laminated, or mixed fabric layer 11, in particular a fabric layer 11 made of natural fibers that is impregnated, laminated, or mixed with a thermoplastic.The fabric layer 11 can, for example, be a film, in particular a prepreg film, comprising a fabric, in particular a woven natural fabric, impregnated or laminated with a thermoplastic. Depending on the material mix, the decorative layer 10 can have an areal density of 100 g / m². 2 up to 2500 g / m 2 , especially 500 g / m 2 up to 580 g / m 2 and in particular 540 g / m 2 The fabric layer 11 can, for example, be a dry prepreg film consisting of a fabric made of natural fibers, in particular flax, which is impregnated, mixed or laminated with a thermoplastic, in particular PP, and has an areal density of 500 g / m 2 up to 580 g / m 2 , especially 540 g / m 2, In order to improve the visual appearance of the vehicle interior trim part 1, the fabric layer 11 can comprise natural, bleached and / or dyed natural fibers.

[0021] The fabric layer 11 may comprise a first type of natural fibers and a second type of natural fibers that differ from the first type. The first type of natural fibers and the second type of natural fibers may differ in at least one property related to tensile strength and color. The difference in tensile strength may be between 50 MPa and 500 MPa, in particular between 100 MPa and 200 MPa. These features, alone or in combination, may contribute to improving the visual and / or tactile performance of the vehicle interior trim part 1.

[0022] The fabric layer 11 can comprise a plurality of untwisted natural fiber yarns or low-twist natural fiber yarns or twisted natural fiber yarns. The fabric layer 11 can comprise at least one plastic, blended, and / or metallic yarn. The fabric layer 11 can comprise a plurality of woven natural fiber yarns, in particular in a twill weave or unidirectional weave or biaxial weave or patterned. In other words, the fabric layer 11 can have different weave types, in particular twill, unidirectional, bidirectional, and / or patterned weave types, and / or different yarn types, in particular untwisted, low-twist, and / or twisted yarn types. The fabric layer 11 can comprise a two-color pattern with a first color in the warp direction and a second color in the weft direction, or any multi-color pattern with, for example, more than one color in the warp direction and more than one color in the weft direction.These features, alone or in combination, may further contribute to improving the visual and / or tactile performance of the vehicle interior trim part 1.

[0023] According to the embodiments of the Fig. 1 and Fig. 2, the decorative layer 10 is adjacent to the substrate 20 and is in contact with it. According to the embodiment of Fig. 1, the decorative layer 10 consists only of the fabric layer 11. According to the embodiment of Fig.2, the decorative layer 10 comprises a further layer 12 arranged between the fabric layer 11 and the substrate 20. Depending on the requirements in the interior, the further layer 12 can be an adhesive layer, a protective layer, a foam layer, or the like. Furthermore, the decorative layer 10 can include a cover layer provided on a side of the fabric layer 11 opposite the substrate 20 (not shown), i.e., the fabric layer 11 can be arranged between the cover layer and the substrate 20. The cover layer can provide additional protection and / or visual effects for the vehicle interior trim part 1. The decorative layer can be an at least partially transparent or translucent layer and can be colored and / or tinted. The decorative layer 10 can include a thermoplastic binder. The support structure 30 is arranged directly adjacent to the substrate 20 and is in contact with it.

[0024] The embodiments of the vehicle interior trim parts 1 described herein provide a factually and visibly increased proportion of natural components, while at the same time achieving similar mechanical properties to meet the minimum requirements for automotive interior applications, with particular attention to weight reduction, mechanical stability, heat aging, environmental cycle testing, UV / light resistance, and scratch resistance. It should be noted that the visibility of the use of sustainable and environmentally friendly materials is increasingly desired by customers, especially in the automotive sector. In general, the respective material mixtures of the decorative layer (10), the substrate (20), and the support structure (30) described above can be selected based on quality requirements while simultaneously improving environmental compatibility.

[0025] A further advantage of the proposed vehicle interior trim parts 1 is their compatibility with various manufacturing processes, including, in particular, one-shot forming, back-injection molding, and / or one-shot forming with back-injection molding. For example, in a first step, the decorative layer 10 and the substrate 20 can be preformed using a compression molding process. In a second step, the support structure 30 can be back-injected onto the preformed decorative layer 10 and the substrate 20. The fabric layer 11 can be provided as a semi-finished product using dry prepreg. Alternatively, foil caulking or impregnation with a thermoplastic resin can be used within a standard lamination process using pressure and heat.The coloring of the fabric layer 11 can be achieved by bleaching and / or dyeing, in particular by dyeing the natural fibers, yarn, or fabric. If the yarn is dyed, a two-color or multi-color pattern of the fabric can be achieved by using differently colored yarns in the warp and weft directions.

Claims

[1] Vehicle interior trim part (1) with a natural fiber composite material, comprising: a decorative layer (10); a rigid support structure (30), in particular a back-injected rigid support structure (30); a natural fiber reinforced plastic substrate (20), in particular an NFPP substrate, which is arranged between the decorative layer (10) and the support structure (30); wherein the decorative layer (10) comprises a natural fiber fabric layer (11) which is at least partially visible from the outside, and wherein the support structure (30) has a plurality of fastening elements (31) and / or stabilizing elements (32). [2] Vehicle interior trim part (1) according to claim 1, wherein the support structure (30) comprises or consists of a polymer material, in particular PP, talc-filled PP, PPGF, foamed plastic, in particular foamed PP and / or natural substance-filled plastic, in particular natural substance-filled PP. [3] Vehicle interior trim part (1) according to claim 1 or 2, wherein the substrate (20) consists of natural fibers, in particular flax, kenaf, hemp, miscanthus, bamboo, jute and / or wood fibers, and polymer fibers, in particular PP and / or PET fibers, wherein the proportion of natural fibers is at least 40% by weight and / or wherein the polymer fibers comprise recycled and / or dyed polymer fibers. [4] Vehicle interior trim part (1) according to one of the preceding claims, wherein the substrate (20) has a surface density of 500 g / m 2 up to 2400 g / m 2 , especially 1000 g / m 2 , has. [5] Vehicle interior trim part (1) according to one of the preceding claims, wherein the fabric layer (11) consists of natural fibers, in particular flax, kenaf, bamboo and / or hemp fibers, and a polymer, in particular PP, wherein the proportion of natural fibers is at least 30 wt. % and / or wherein the fabric layer (11) is an impregnated, laminated or mixed fabric layer (11), in particular a fabric layer (11) made of natural fibers which is impregnated, laminated or mixed with a thermoplastic. [6] Vehicle interior trim part (1) according to one of the preceding claims, wherein the decorative layer (10) has a surface density of 100 g / m 2 up to 2500 g / m 2 , especially 500 g / m 2 up to 580 g / m 2 and in particular 540 g / m 2 has. [7] Vehicle interior trim part (1) according to one of the preceding claims, wherein the fabric layer (11) comprises natural, bleached and / or dyed natural fibers. [8] Vehicle interior trim part (1) according to one of the preceding claims, wherein the fabric layer (11) comprises a first type of natural fibers and a second type of natural fibers, wherein the first type of natural fibers and the second type of natural fibers differ in at least one property with respect to tensile strength and color. [9] Vehicle interior trim part (1) according to one of the preceding claims, wherein the fabric layer (11) comprises a plurality of untwisted natural fiber yarns or low-twisted natural fiber yarns or twisted natural fiber yarns and / or at least one plastic, mixed and / or metal yarn. [10] Vehicle interior trim part (1) according to one of the preceding claims, wherein the fabric layer (11) comprises a plurality of woven natural fiber yarns, in particular in twill weave or unidirectional weave or biaxial weave or pattern.

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